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Make Projects 

build, hack, tweak, share, discover,^ 


Written By: Chris Connors 



Scissors (1) 
Seam ripper (1) 
Sewing needle (1) 


Headphones. 1/8" plug, mono or stereo 


hat with ear flaps (1) 


Winter is finally here in Massachusetts. While digging in the 'Hats' plastic tub today, I 
happened upon a flappy hat from last year. SantaMaker recently brought me some cheap 
headphones, and a few amplified speakers too (but those are for another project). Tonight 
turned out to be the time to merge the two into a HeadphoneHat. I've been thinking of the 
Rock Star Headphones project in Fashioning Technology as an inspiration for a way to take 
music on the go. There is a similar project in Diana Eng's book Fashion Geek . 

First thing was to gather all the stuff: Headphones, a flappy hat, a nice sharp pair of shears, 
a seam ripper, some thread and a needle were all this project called for. 

You can view my photos of making the first HeadphoneHat on Flickr . 

© Make Projects 

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Step 1 — HeadphoneHat 

• Gather the supplies: 

• A flappy hat 

• Headphones with speakers that are 
smaller than the flaps (not earbuds) 

• Scissors or shears 

• Seam ripper 

• Thread to match the hat 

• Needle 

Step 2 

• Open up the seam on the back side 
of the flap 

• I used a seam ripper, but you could 
carefully cut with scissors or a 
utility knife. 

• You don't want the bottom to be 
open, as the speakers will fall out. 

• You don't want the front edge of the 
flap to have the hole, as it will look 
ugly with the wire showing forward. 

• Usually, flappy hats have the flaps 
slightly to the rear of the hat. 

© Make Projects 

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Step 3 

• Test to see if you can fit the 
speaker into the hole you just made 
in the seam. 

• If not, open the seam up a bit. 

• Pop the speaker in and position it. 

• Make sure the speaker is facing 
the inside of the hat. 

Step 4 

• Reinforce the seam at both ends of 
the opening you made. 

• Test to see if you can get the 
headphones out. 

• If your opening is too narrow, rip 
out one of your reinforcements and 
make the hole a little wider. 

• Leaving the hole a little small is 
good so the speakers don't fall out. 

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Step 5 

• Try out your hat. 

• You may need to position the 
speakers so they sit over your ears 

• You could add some sticky backed 
hook and loop to the back of the 

• You may be able to use just the 
hook side and have it stick to the 
fabric of the flap. 

Step 6 

• Use your hat. 

• Show it to your friends. 

• Try it with your phone. 

• Ask your friends what features you 
might add. 

• Make another. 

• Give it away or sell it. 

This document was last generated on 2012-11-03 02:29:48 AM. 

© Make Projects 

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